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Last Modified:
08-30-2021
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6.10:8.0.50
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Doc ID:
RM100000001H0GX
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Model Year Start:
2019
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Model:
Prius
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Prod Date Range:
[12/2018 - 07/2020]
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Title:
HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL; 2019 - 2020 MY Prius [12/2018 - 07/2020]
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REMOVAL
CAUTION / NOTICE / HINT
The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during inverter with converter assembly removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure
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Necessary Procedures
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Effect/Inoperative Function when Necessary Procedure not Performed
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Link
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Auxiliary battery terminal is disconnected/reconnected
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Memorize steering angle neutral point
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Lane departure alert system (w/ Steering Control)
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Intelligent clearance sonar system*1
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Simple advanced parking guidance system*1
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Pre-collision system
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AFS (Adaptive Front-lighting System)
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Initialize back door lock
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Power door lock control system
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Replacement of inverter with converter assembly
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Resolver learning
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DTCs are stored
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Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
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Shock or vibration during acceleration
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for Nickel Metal Hydride Battery
for Lithium-ion Battery
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Replacement of ECM
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Perform Vehicle Identification Number (VIN) registration
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MIL comes on
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PROCEDURE
1. PRECAUTION
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
Click here
2. DISCONNECT ENGINE WIRE
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(a) Disengage the 2 claws and disconnect the engine wire from the battery current sensor holder.
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(b) Disconnect the battery state sensor assembly connector.
3. REMOVE AUXILIARY BATTERY
Click here
4. REMOVE SERVICE PLUG GRIP
Click here
5. REMOVE REAR MOTOR UNDER COVER LH
Click here
6. DRAIN COOLANT (for Inverter)
Click here
7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
Click here
8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Click here
9. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL
Click here
10. REMOVE WATER GUARD PLATE LH
Click here
11. REMOVE COWL BODY MOUNTING REINFORCEMENT LH
Click here
12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY
Click here
13. REMOVE ECM
Click here
14. REMOVE BATTERY CLAMP SUB-ASSEMBLY
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(a) Remove the 3 bolts and battery clamp sub-assembly.
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15. DISCONNECT ENGINE WIRE
CAUTION:
Wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter assembly.
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(a) Remove the No. 1 relay block cover.
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(b) Disconnect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.
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(c) Disengage the 2 claws.
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(d) Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.
NOTICE:
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Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
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Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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Insulate the disconnected terminals with insulating tape.
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Do not touch the waterproof seal or terminals of the connector.
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(f) Disengage the clamp (A) and remove the inverter protector.
(g) Disengage the clamp (B).
(h) Remove the bolt.
(i) Disengage the 2 clamps and disconnect the engine wire.
16. REMOVE CONNECTOR COVER ASSEMBLY
CAUTION:
Wear insulated gloves.
(b) Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.
NOTICE:
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Do not touch the connector cover assembly waterproof seal.
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
17. CHECK TERMINAL VOLTAGE
CAUTION:
Wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter assembly.
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(a) Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.
Standard Voltage:
0 V
HINT:
Use a measuring range of DC 750 V or more on the voltmeter.
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18. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY
CAUTION:
Wear insulated gloves.
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(a) Temporarily install the connector cover assembly to the inverter with converter assembly.
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(b) Using a T25 "TORX" socket wrench, install the bolt.
Torque:
4.5 N·m {46 kgf·cm, 40 in·lbf}
NOTICE:
Do not touch the waterproof seal of the connector cover assembly.
19. DISCONNECT HV FLOOR UNDER WIRE
CAUTION:
Wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter assembly.
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(a) Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.
NOTICE:
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Do not touch the waterproof seal or terminals of the connector.
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Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
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Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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Insulate the disconnected terminals with insulating tape.
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(b) Disengage the 2 clamps.
20. DISCONNECT AIR CONDITIONING WIRE
CAUTION:
Wear insulated gloves.
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(a) Remove the 2 bolts and disconnect the air conditioning wire from the inverter with converter assembly.
NOTICE:
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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Do not touch the waterproof seal or terminals of the connector.
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Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
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Insulate the disconnected terminals with insulating tape.
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Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
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(b) Disengage the clamp.
21. REMOVE WIRE HARNESS CLAMP BRACKET
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(a) Remove the nut and wire harness clamp bracket.
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22. DISCONNECT NO. 3 ENGINE WIRE
CAUTION:
Wear insulated gloves.
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(c) Disengage the 2 claws and open the No. 3 engine wire terminal cover.
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(e) Disengage the clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.
23. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE
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(a) Slide the clip and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly.
NOTICE:
Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.
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24. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE
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(a) Slide the clip and disconnect the inlet No. 1 inverter cooling hose from the inverter with converter assembly.
NOTICE:
Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.
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25. REMOVE INVERTER COVER
CAUTION:
Wear insulated gloves.
(a) Remove the 2 bolts and inverter cover from the inverter with converter assembly.
NOTICE:
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Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
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Do not touch the waterproof seal of the inverter cover.
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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When removing the inverter cover, do not pull the areas (A) as they may deform.
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Make sure that the interlock is installed to the inverter cover.
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Do not remove or excessively tighten the screw of the inverter cover.
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*1
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Inverter Cover
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*a
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Screw
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Although the inverter cover may feel loose, this is not due to a malfunction.
HINT:
If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.
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*a
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Interlock
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*b
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Waterproof Seal
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26. DISCONNECT MOTOR CABLE
CAUTION:
Wear insulated gloves.
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(a) Using an insulated tool, remove the 6 bolts.
NOTICE:
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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Do not touch the waterproof seal or terminals of the connector.
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(b) Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.
NOTICE:
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Do not allow any foreign matter or water to enter the inverter with converter assembly.
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Do not touch the waterproof seal or terminals of the connector.
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Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
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Insulate the disconnected terminals with insulating tape.
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After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
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Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
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To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
27. REMOVE INVERTER WITH CONVERTER ASSEMBLY
CAUTION:
Wear insulated gloves.
(a) Remove the 5 bolts, 2 nuts and inverter with converter assembly.
NOTICE:
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When removing the inverter with converter assembly, be careful not to damage the parts around it.
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To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
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To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
HINT:
Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.
28. REMOVE NO. 1 INVERTER BRACKET
(a) Set the inverter with converter assembly on wooden blocks.
NOTICE:
Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.
(b) Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.
29. REMOVE NO. 2 INVERTER BRACKET
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(a) Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
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30. REMOVE WIRE HARNESS CLAMP BRACKET
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(a) Remove the 2 bolts and 2 wire harness clamp brackets from the inverter with converter assembly.
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(b) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
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(c) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
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